Busted Head studs

[JRGC94]

hey guys
i have a GC Galant with a 4G32 motor in it, we were trying to replace the head gasket as it leaks, because it is over 30yrs old, as we were undoing the head studs, which are an allen headed bolt, we stripped one, we tryed to remove it with a impact wrench and have had no luck, we'd prefer not to drill it if we can. But does anyone know/have any good ideas on how to remove one?
any help greatly appreciated.
Cheers
Tom

[davetrees]

Why not drill it & use an easy-out ? You're going to have to re-tap the hole anyway, if the thread is stripped ....

Note - new genuine 4G32 head bolts are NLA (unless they happen to match something else) but it's fine to use good s/hand ones .... they don't stretch when you torque them up.

[75wagon]

Is it in a place where you can get to it with a grinder (most likely not). But if you can, grind off the head of the bolt. Then pull the head off and use vice grips on the shaft.

Dave...

[geezer101]

I'd still go for the drill and gently remove the stripped out socket head on the bolt- you'll have way more control over the whole process. The chance of hitting something with a wayward angle grinder in the confined space of the head is too high plus the amount of grinding debris flying around will invariably end up somewhere you really don't want it...

[C_Fernance]

What about welding a nut to it, then using a normal socket on the nut?

[A112H]

+1 for welding on a nut and using a socket.
But, you could see this as the perfect oportunity to ditch the Saturn and slip an Astron in there, lol

[HEMI26]

+2 for welding a nut on and using a socket

[davetrees]

Ah ... you mean you stripped the in- hex head on the bolt ? I assumed you meant you stripped the thread (although I did wonder how you managed to do that .....) What happened .... wrong size or cheap quality hex key ?

Welding a nut onto it is probably the easiest then .... or just use a hammer & punch & tap it around in circles .... that's how I got one of mine out earlier this year after I snapped the head off it.

[75wagon]

That's all good about the welding on a bolt, but the next question is: Does he have access to a welder?
I agree, it would be the best method, but the standard DIY'ers garage would generally not have one.

Dave...

[davetrees]

Another option ..... depending how badly the head is stripped, belt a slightly oversize hex key into it ?

[A112H]

Either way it seems we are having this conversation without the original poster, lol

[Superscan811]

Another option ..... depending how badly the head is stripped, belt a slightly oversize hex key into it ?

A good quality oversized torx (star) I find works better.

Cheers..

[JRGC94]

thanks for the help guys, we actually have a pretty well equipped work shop, mill, lathe, stick, mig welders, drill press, more tools than you can poke a stick at, so we have the resources. my father managed to drill the top out and we managed to undo it by hand after that... go figure! but got it out without damaging the head, cam, valves and so on. will be replacing all the studs, thanks for all the tip's, greatly appreciated!
Cheers
Tom